Tape drive conveyor system with twisted conformation

ABSTRACT

A flexible drive tape conveyor system for conveying items between at least two spaced apart stations includes a carrier member and at least one tape guide track having a tape guide. The drive tape is substantially inflexible in a direction transverse to its width, and is at least partially housed in the tape guide. At least a portion of a tape guide track and tape guide are twisted about their longitudinal axis so that the drive tape and its affected carrier member can be turned in a direction transverse to the width of the drive tape. A drive mechanism is used to selectively reciprocate the drive tape and the carrier member between the spaced apart stations.

This is a division of application Ser. No. 08/699,397 filed Aug. 19,1996, now U.S. Pat. No. 5,791,451.

TECHNICAL FIELD

This invention relates to an improved conveyor system for use indrive-in banks and other remote transaction applications, wherein aflexible yet relatively longitudinally rigid drive tape is reciprocatedbetween two or more spaced apart stations and wherein at least a portionof the drive tape is rotated about its longitudinal axis to twist thetape in a direction transverse to its width.

BACKGROUND OF THE INVENTION

In a growing variety of business applications, it is desirable and/ornecessary to convey items such as currency, documents, food, messagesand other items between spaced apart locations or stations. In manysituations, a somewhat flexible, yet relatively longitudinally rigid,drive tape provides a reliable yet highly adaptable drive system whichminimizes the requirements for expensive and inconvenient pneumaticset-ups or long lengths of chains and/or complex gearing arrangements toadapt to twists and turns along the transport path.

For example, U.S. Pat. No. 5,054,605, herein called the '605 Patentwhich issued on Oct. 8, 1991 to Edward F. Bavis, shows and describes apreferred flexible drive conveyor system for use in drive-in banks andother remote transaction applications. Particularly, the Bavis '605Patent sets forth a relatively simple and reliable conveyor systemutilizing flexible tape as the drive medium. As set forth in thispatent, the width and depth of the tape guide provided for the drivetape, is to be chosen to accommodate the natural tendency of the tape tobend somewhat under compression in a sinuous manner.

Additionally, U.S. Pat. No. 5,232,408, which issued to the presentinventor, Michael E. Brown, sets forth an improved method ofreciprocating a flexible drive tape about a cog wheel. At high speed,and/or high loads, flexible drive tapes have a tendency to fold and/orbind within the tape guides on either side of the cog wheel. The Brown'408 conveyor system provides an improved arrangement including peelertips which significantly reduce the binding and/or folding of the drivetape as it is reciprocated about the cog wheel.

While the flexible tape drive conveyor systems disclosed in the priorBavis and Brown patents provide many benefits over other conveyorsystems known to the art, such as pneumatic and chain conveyors,flexible drive tapes in general have an additional characteristic whichhas heretofore limited the use of such systems. In order for anon-continuous drive tape to be both pushed and pulled within a tapeguide, the drive tape must be essentially rigid in a directiontransverse to the width of the tape. Thus, while the drive tape bendseasily in a direction along its longitudinal axis, which allows it tocurl around a cog wheel and to follow around curves and turns in theconveyor path along that longitudinal axis, the drive tape does not bendeasily in a direction transverse to its width. In fact, the drive tapemust have a certain amount of rigidity to optimally enable the “push andpull” requirements of a non-continuous, single drive setup.

The essential rigidity of the drive tape in at least one direction,however, has made it difficult in the past for a drive tape to bemanipulated in a direction transverse to its width. Thus, it has beendifficult for drive tape conveyor systems of the past to negotiatearound obstructions or to make simple turns in a direction transverse tothe drive tape width.

Chain link conveyors, non-rigid belt conveyors, rope conveyors and thelike have been adapted to make turns in a direction both transverse totheir width and their length. However, these conveyer systems require acontinuous loop system because the same substantial flexibility of thedrive belt (e.g. chain link, rope, canvas belt) which allows the belt tobe turned in a direction transverse to its width also restricts thedrive belt's ability to be both pushed and pulled without being acontinuous loop or without having a drive mechanism at each end of thesystem.

For example, U.S. Pat. No. 1,786,343 to Griffith, shows a continuousloop flexible conveyor belt system wherein the belt is twisted throughthe use of rollers so that it can travel in a direction transverse toits width. However, the belt in Griffith is continuous, and, presumably,the flexibility which allows the conveyor belt to be turned in adirection transverse to its width also renders the belt too flexible tobe both pushed and pulled within a guide track. Likewise, U.S. Pat. No.4,556,143 to Johnson shows a chain link drive mechanism wherein, due tothe inherent flexibility between links in the chain, the chain can begradually turned about a large radius in the direction transverse to thechain's width, see FIG. 8 of Johnson. The chain link drive in Johnsonmust also be continuous, however, because the inherent flexibilitybetween links in the chain causes the chain to substantially collapsewhen its direction of travel is changed unless the chain is continuous.

An endless transmission belt conveyor system for moving bobbins is shownin U.S. Pat. No. 5,097,943 to Kawasaki, et al., wherein a continuousseries of ropes or belts are used to both propel the bobbins and guidethem about a predetermined path. However, the belts and/or ropesdisclosed in the Kawasaki, et al. patent are continuous andsubstantially flexible in all directions.

Hence, continuous flexible conveyor systems which can be turned in avariety of directions are known. Unfortunately, however, the flexibilitywhich allows continuous belt, chain, or rope conveyor systems to bemanipulated in a multitude of directions also makes them generallyunsuitable for a non-continuous drive belt system wherein substantialrigidity is required so that a drive tape or similar drive mechanism canwithstand both compressive and tensing forces without substantialbuckling, stretching, and/or decreases in the tape length.

Thus there is a need for a simple, inexpensive yet reliable conveyorsystem for moving items between spaced apart stations wherein theconveyor system can accommodate changes in essentially all directions tonegotiate around obstructions, turn comers and the like. The presentinvention responds to those needs.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an improved tapedrive conveyor system which obviates the problems discussed above.

It is a related object of the present invention to provide an improvedtape drive conveyor system wherein the drive tape can be rotated aboutits longitudinal axis so that it can be moved and/or-manipulated in adirection transverse to its width.

It is also an object of the present invention to provide an improvedtape guide wherein the tape guide has a twisted conformation about itslongitudinal axis such that the tape guide can rotate a drive tape andits attached carrier about its longitudinal axis in a directiontransverse to the drive tape width.

These and additional objects are provided by the present invention.Specifically, the invention, in one embodiment, is directed to animproved conveyor system for reciprocating a carrier member between aplurality of stations. The system comprises a reciprocable, flexibledrive tape having a longitudinal axis and a predetermined width whereinthe tape is substantially inflexible in the direction transverse to itswidth. A drive mechanism engages the drive tape and selectivelyreciprocates the drive tape and a carrier member attached theretobetween a plurality of spaced apart stations. The drive tape is at leastpartially housed in a tape guide which has a longitudinal axis and atleast a portion of the tape guide is twisted along its longitudinal axiswhereby the drive tape and an attached carrier member may be selectivelyreciprocated and manipulated both longitudinally and in directionstransverse to the width of the drive tape.

In a preferred embodiment of the present invention, the tape guidefurther comprises a longitudinal channel extending along thelongitudinal axis of the tape guide for receiving and guiding the drivetape. The tape guide preferably has an outer surface wherein both thelongitudinal channel and the outer surface of the tape guide are twistedalong the longitudinal axis of the tape guide so that the outer surfaceis at least partially rotated relative to the longitudinal axis of thetape guide. The longitudinal channel is preferably twisted between about0° and 90° relative to its longitudinal axis.

In another embodiment of the present invention, the improved conveyor;system comprises a flexible drive tape having a longitudinal length anda predetermined width wherein the drive tape is substantially inflexiblein a direction transverse to its width. A tape guide is provided whereinthe drive tape is at least partially housed. The tape guide has two endsand a longitudinal axis extending therein between, with at least aportion of the tape guide having a twisted confirmation along itslongitudinal axis so that the drive tape can be selectively reciprocatedwithin the tape guide and the drive tape can be manipulated in adirection transverse to the width of the drive tape.

The improved drive tape conveyor system of the present invention allowsa carrier member attached to the drive tape to be selectivelyreciprocated between at least two spaced apart stations and wherein thedrive tape and carrier member attached thereto can be manipulated aroundpoles, trees, walls and other obstructions which may exist between thespaced apart stations.

These and additional objects and advantages will be more apparent inview of the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the present invention, it is believed that thesame will be better understood from the following description taken inconjunction with the accompanying drawings in which:

FIG. 1 is a schematic isometric view of a conveyor system made accordingto the present invention showing various tape guide track sections,spaced apart stations and a drive mechanism;

FIG. 2 is a partial schematic representation of a portion of a conveyorsystem of the present invention, showing a tape guide track rotatedapproximately 90° about its longitudinal axis;

FIG. 3 is a partial elevational view of a carrier member attached to adrive tape which is partially housed in a tape guide;

FIG. 4 is a cross-sectional view of the carrier member, tape guide trackand drive tape of FIG. 3, taken along line 4—4 thereof;

FIG. 5 is a longitudinal partial cross-section of the carrier member,tape guide track and drive tape of FIG. 3 taken along line 5—5 thereof;and

FIG. 6 is an isometric view of preferred embodiment of a carrier memberof the present invention having a selectively reciprocated doormechanism.

DETAILED DESCRIPTION

Referring now to the drawings in detail, wherein like numerals indicatethe same elements throughout the views, FIG. 1 is a schematic isometricview of a conveyor system made according to the present invention.Specifically, FIG. 1 shows a conveyor system 7 which comprises aplurality of tape guide track sections, e.g. 29, 13 and 16, spaced apartstations 8, 80 and 81, a drive mechanism 9, a communication device 90and a support attachment bracket 31. A drive tape, which is shown ingreater detail in FIGS. 2 through 6, can be reciprocated within the tapeguide sections, e.g. 29, 13, and 16, between spaced apart stations,e.g., 8, 80 and 81. A carrier member 10, which can be attached to thedrive tape, is reciprocated with the drive tape between spaced apartstations. All of the individual units of the conveyor system 7 arediscussed in greater detail below.

Prior flexible conveyors were restricted in that a drive tapereciprocated between spaced apart stations could not be turned in adirection transverse to its width. Drive tapes used in conjunction withthe present invention are substantially inflexible in a directiontransverse to their width, which heretofore has seriously limited therange of motion for prior art conveyor systems. As will be understood,the use of twisted tape guide track sections, e.g., 13, alleviates therestrictions of prior conveyor systems and increases the range of motionfor the conveyor systems of the present invention. Thus, a carriermember (e.g. 10) attached to a drive tape at least partially housed in atape guide track section (e.g. 16,13 and 29) has essentially unlimitedrange of movement through the use of straight guide track sections, e.g.29, bent tape guide track sections, e.g. 16, and twisted tape guidetrack sections, e.g. 13. The tape guide track sections, e.g. 29, 16 and13 are shown as modular units, but as will be understood, one tape guidetrack section could be bent and/or twisted as desired to form a conveyorsystem comprising only one tape guide track section. Likewise, aconveyor system, e.g. 7, can be assembled through the use of individualtape guide track sections which are straight, e.g. 29, twisted, e.g. 13,and/or bent, e.g. 16. Thus, the combination of tape guide track sectionsis essentially unlimited and the direction of travel of the reciprocateddrive tape can be maneuvered through the appropriate combination of tapeguide track sections to avoid obstructions and to negotiate corners andthe like.

FIG. 2 is a partial schematic representation of a twisted tape guide anddrive tape arrangement made according to the present invention.Specifically, FIG. 2 discloses two 90° angle tape guide track sections16 which have been bent in a direction transverse to their length, and atwisted tape guide track section 13 which has been rotated (e.g. in adirection R) about its longitudinal axis A2. Tape guide track sections16 and 13 respectively define a part of a tape guide 15 having alongitudinal channel 14 for guiding drive tape 12 and a longitudinalaxis A2. A longitudinal opening 18 is provided in tape guide 15 which issubstantially parallel to longitudinal axis A2. As will be understood,drive tape 12 can be selectively reciprocated within channel 14. Drivetape 12 has a longitudinal axis A1 and as drive tape 12 is selectivelyreciprocated within longitudinal channel 14 of guide track section 13,the longitudinal axis A1 of drive tape 12 will preferably remainsubstantially parallel to the longitudinal axis A2 of longitudinalchannel 14. Consequently, as will be explained, rotating or twistinglongitudinal channel 14 about its longitudinal axis A2 necessarilyrotates drive tape 12 about its longitudinal axis A1 as drive tape 12 isreciprocated therewithin.

Tape guide track section 13 is illustrated as including an outer surface26 which faces outwardly and laterally prior to the twist of tape guidetrack 13. Tape guide track section 13 is shown in FIG. 2 as beingtwisted about its longitudinal axis A2 in the direction R. As a resultof such rotation, outer surface 26 (which was facing outwardly andupwardly in a direction U) faces outwardly and laterally (i.e., in adirection L) after being twisted. Likewise, carrier member 19 is shownin a second position after being reciprocated across guide track section13 so that the outer surface 17 of carrier member 19 faces laterally(i.e., in a direction L). As can be appreciated, the longitudinal axisA1 of drive tape 12 and the longitudinal axis A2 of guide track section13 remain substantially coaxial to one another at each point alongtwisted guide track section 13.

Also shown on FIG. 2 are drive tape perforations 11. Drive tapeperforations 11 serve at least two purposes, they can be used to connectthe carrier member, e.g., 19 to drive tape 12 with a connector (as shownin greater detail in FIGS. 3, 4 and 5 and is discussed in greater detailbelow). Additionally, perforations 11 interact with the cogs of a cogwheel which is driven by a drive mechanism, e.g. 9, as shown in FIG. 1to selectively reciprocate drive tape 12 within longitudinal channel 14.U.S. Pat. No. 5,232,408 (the '408 Patent) to Michael Brown, discloses acog wheel, drive mechanism and drive tape system for a flexible drivetape conveyor system. The entire disclosure of the '408 Patent is herebyincorporated herein by reference. As can be appreciated and as will bediscussed in greater detail below, longitudinal opening 18 allows amechanical connector or connectors between the carrier member (e.g. 10,FIGS. 4 and 5) and the drive tape (e.g. 12, FIGS. 4 and 5) to passunobstructed while the carrier member is reciprocated along tape guidetrack sections (e.g. 22, FIGS. 4 and 5).

FIG. 3 is a partial view of a carrier member 10 attached to a drive tape12 via first and second attachment blocks 45 and 46, respectively. Whileit is preferred to utilize a plurality of attachment arrangements toprovide for adequate stability of carrier member 10 with a drive tape12, it should be understood that in some applications one attachmentpoint, and in other applications, more than two attachment points, maybe desirable and/or appropriate. The size, shape and weight of carriermember 10 will largely influence the number and type of attachmentstructures necessary. A preferred embodiment of the present inventionwill be described in conjunction with the carrier member 10 which has awidth W1 which is slightly larger than the width W2 of tape guide tracksection 22.

It may be desirable in many applications to minimize unnecessary contactbetween carrier member 10 and tape guide track 22 during thereciprocation of drive tape 12. FIG. 4 shows a cross-sectional view ofcarrier member 10, tape guide track 22, drive tape 12 wherein there areprovided two predetermined gap distances D2 and D3 between the underside27 of carrier member housing 28 and outer surface 26 of tape guide tracksection 22. As will be understood, distances D2 and D3 can vary fromtime to time in use as carrier housing 28 leans towards one side or theother of track 22. For example, the load within carrier member housing28 may shift from one side to the other, or the orientation of carriermember housing 28 can change as carrier 10 is reciprocated over atwisted guide track section, for example, 13, as shown in FIG. 2.

To avoid unnecessary frictional wear on the carrier member 10, itsunderside 27 and track 22 and to minimize undue resistance and drag, itis preferred to maintain D2 and D3 greater than 0 on both sides of guidetrack 22. A preferred method for maintaining a space between the carriermember underside 27 and guide track 22 is through the use of runners 30.Runners 30 can be manufactured from any of a variety of availablematerials including metals, hard plastics, rubber and the like andshould generally be compatible with the materials of guide track 22 toavoid galling or unnecessary wear when the two surfaces contact oneanother. It is even more preferred to provide at least one rotatingcontact between carrier member receptacle 28 and guide track 22. Apreferred rotating contact is shown in FIGS. 3, 4 and 5 as a combinationof wheels 32 and axle 36. The rotating contact can be any of a varietyof known rollers in the art, e.g. casters, wheels bearings and the like.Likewise the rotating contact can be made from any appropriate materialssuch as rubber, hard plastic and metals.

As is best shown in FIGS. 3, 4, and 5 axle 36 is preferably connected toattachment block 45 and to drive tape 12 with bolt 44 having an enlargedbolt head 42 which secures attachment block 45 to drive tape 12 througha perforation 11. A recess 40 is also preferably provided in tape guide15 to accommodate bolt head 42 as carrier member 10 and drive tape 12are reciprocated.

It is generally necessary for axle 36 to have some freedom of movement,as is shown in FIGS. 3 and 5. In the embodiments illustrated, thefreedom of movement for axle 36 is provided by slots 50 in mountingbraces 34. There are two mounting braces 34, each having a slot 50,wherein each mounting brace 34 is fixedly attached to the underside 27of carrier member receptacle 28 to provide the necessary connectionbetween carrier member 10 and drive tape 12. As will be understood, axle36 is free to move within slot 50 of mounting brace 34 in a directionparallel to longitudinal axis A1 of drive tape 12, and (as a result ofrelative movement in the respective slots 50) to rotate in a limitedmanner within a plane which is parallel to both the underside 27 ofcarrier receptacle 28 (as indicated in FIG. 3). Thus, as a drive tape istwisted (e.g. drive tape 12 within guide track 13, FIG. 2) or as a drivetape is bent around a 90° bend (e.g. drive tape 12 within guide tracksection 16, FIG. 2) it is especially preferred that the two connectionsto the underside 27 of carrier receptacle 28 allow at least some limitedflexibility to accommodate for the changes in distances D1, D2 and D3 asa drive tape 12 is manipulated. The underside 27 of carrier receptacle28 can be substantially rigid, and if all connections to the drive tape12 were also rigid attachments to underside 27, unnecessary strain maybe placed on both drive tape 12 and attachment bolts 44 as well as theattachment to underside 27. Provision of slots 50 or other structures toprovide some tolerance for movement, allow axle 36 to move in adirection substantially parallel to the longitudinal axis A1 of drivetape 12 and slots 50 provide axle 36 with the ability to rotate in aplane substantially parallel to drive tape 12, thus, helping to reduceor eliminate the stresses which would otherwise be placed on attachmentbolts 44 and drive tape 12 as the drive tape 12 is bent and/or twistedwithin a tape guide, e.g. 13 and 16 of FIG. 2.

For similar reasons, it is preferred to use a swivel connection, forexample universal joint 38, as shown in FIG. 4 and 5 for at least one ofthe connections between carrier receptacle 28 and drive tape 12.Universal joint 38 is illustrated as comprising a shaft 47, a swivelhousing 52 and a swivel 49 wherein the shaft of bolt 48 fits within theswivel 49 of Universal joint 38. As bolt 48 contacts the swivel housing52 of universal joint 38, the universal joint swivel 49 is restricted inmovement. The use of a universal joint is intended to further reducepotential stresses and strains on drive tape 12 and attachment bolt 44by allowing for limited movement of the attachment means between carriermember 10 and drive tape 12. As discussed above, such limited movementof the attachment means is preferred to accommodate for a variety ofstresses and strains transmitted to the attachment block (e.g. 45 and46) as drive tape 12 is twisted and/or bent within a tape guide tracksection. As can be appreciated, other appropriate connectors andconnection arrangements, for example flexible couplings, springs,hydraulic shafts and the like may be substituted to accomplish thesesame purposes. Additionally, simpler means for connecting carrier member10 to drive tape 12 can be used, including one or more rigid bolt-likeconnections.

An especially preferred method for reducing wear on attachment blocks 45and 46 is to place a bearing, sleeve or other rolling device ofgenerally cylindrical geometry, e.g. rollers 41 and 43, on theattachment bolt, e.g. 42. Rollers 41 and 43 can be made of any materialthat is frictionally compatible with longitudinal opening 18 andattachment bolt 42, for example, an oil impregnated brass sleeve isespecially preferred for rollers 41 and 43. Rollers 41 and 43 shouldhave an exterior diameter which is less than the width of longitudinalopening 18 so that they are normally spaced apart from longitudinalopening 18. Contact between rollers 41 and 43 and longitudinal opening18 occurs generally when the weight of the carrier member, e.g. 19, FIG.1, is shifted, for example when carrier member 19 traverses twistedtrack 26. The spacing between rollers 41 and 43 and longitudinal opening18 is a design consideration within the skill of one of ordinary skillin the art. Preferred spacing between rollers 41 and 43 and longitudinalopening 18 is in the range of from about 0.030″ to about 0.050″ (fromabout 0.8 mm to about 1.3 mm).

The drive mechanism (e.g. 9, FIG. 1) used to reciprocate drive tape 12,and subsequently any and all carrier members attached thereto, cangenerally be any drive wheel, cog or the like, which is rotatably drivenby a reversible motor. U.S. Pat. No. 5,054,605 (the '605 Patent) toEdward F. Bavis, gives a detailed description of an appropriate drivemechanism for a flexible tape drive conveyor system. The entiredisclosure of the '605 Patent is hereby incorporated herein byreference. Additionally, the '408 Patent, which has been incorporatedherein by reference above, also discloses a cog drive wheel drive motor(collectively the drive mechanism) and flexible drive tape arrangement.Likewise, the '605 and '408 Patents described flexible drive tapes whichcan be utilized herein. One suitable material which can be utilized fordrive tape 12 is “dymetrol” tape available from E. I. duPont deNemoursand Company of Fayettville, N.C. The present invention is describedherein in conjunction with one preferred embodiment for the drive tape12 which, as can be seen in the cross-sectional view in FIG. 4, thethickness TT of the tape is substantially less than the width TW of thetape. The cross-sectional view of drive tape 12 shown at FIG. 4 is onlyone possible embodiment of the present invention and is not meant to belimiting. The cross-sectional configuration of drive tape (e.g. 12, FIG.4), in conjunction with a drive tape material, which is substantiallyrigid so that it can be both pushed and pulled within a tape guidewithout substantial deformation or collapse, renders drive tape 12substantially inflexible in a direction transverse to its width, as isbest seen in FIG. 3 by the directional arrow T. Thus, moving the drivetape in a direction T transverse to its width TW is substantiallyrestricted by the material of manufacture and the cross-sectionalgeometry of drive tape. However, the substantial transverse rigidity ofthe drive tape and its cross-sectional configuration make the drive tapesuitable for non-continuous, reciprocating drive arrangements. In otherwords, the rigidity of the drive tape which makes it suitable fornon-continuous reciprocation conveyor systems is the same rigidity whichrestricts its movement in a direction T transverse to its width TW. Aswill be appreciated, to support and guide a drive tape, e.g. 12, theguide track sections, e.g. 13, 16, and 22, must have substantialrigidity while having enough malleability to be twisted and/or bent,e.g. guide track sections 13 and 16, to provide the necessary bent,straight and/or twisted confirmation required by the present invention.

Guide track sections 13, 16 and 22 can be made from any suitablematerial. High density plastic, metals and the like are all suitablematerials for guide track construction. However, when the tape guidetracks are formed of relatively smooth, rigid materials such as anodizedaluminum, no additional lubrication generally is necessary forcontinuous and reliable operation of drive tape 12. Likewise, an ultrahigh molecular weight, self-lubricating plastic can provide the samesmooth reliable operation. However, a plastic guide track may needadditional support structures (e.g. support bracket 31, FIG. 1) whereasan aluminum or other metal guide track can serve as its own support forthe drive tape/carrier member combination. Additionally, drive tapeguide tracks can be provided as modular segments, or one guide track canbe twisted, bent and/or straightened to provide a conveyor systemcomprising only one guide track section.

Drive tape guide tracks can be manufactured by any suitable means, forexample, machining, molding, forging, extruding and the like. The sizeand shape of the longitudinal channel 14 and longitudinal opening 18will be dictated by the drive tape and attachment means respectively.While not intending to be limited to any particular size or geometricconfiguration, a longitudinal channel having a width of from about 0.5to about 0.7 cm and a length of from about 1.0 to about 1.5 cm has beenused in conjunction with a drive tape within the same ranges. Thedimensions of the longitudinal channel (i.e. length and width) should befrom about 5.0% to about 10.0% larger than the dimensions of the drivetape to avoid binding and unnecessary friction within the longitudinalchannel. The length of the longitudinal opening will necessarily bedictated by the size of the attachment means and the opening shouldgenerally not exceed 85% of the longitudinal channel's width.

Guide track sections can be provided with one tape guide, asschematically shown in FIG. 2, or a guide track section, for example,guide track section 22, can be provided with a first tape guide 15 and asecond tape guide 24 for partially housing drive tape 12. The '408 andthe '605 Patents discussed above, contain additional discussion of thesecond tape guide, which can be used to partially house the drive tapeafter it has been reciprocated around the drive mechanism. As shown inFIG. 4, the tape guide track 22 can be hollow, which provides space torun wires, sensors and the like on the inferior of the track, leavingthe exterior free of material which might interfere with the operationof the drive tape and/or carrier member.

A variety of alternatives are available for manufacturing twisted guidetracks of the present invention, e.g. 13 of FIG. 2. For example, a trackmade from a malleable plastic, e.g., polypropylene, polyethylene and thelike can be readily twisted by securing one end of the track, twistingthe track to the desired angle and securing the opposite end of thetrack. Likewise, a metal guide track, e.g. aluminum, steel, stainlesssteel, can be mechanically secured at both ends and then mechanicallytwisted to the desired angle of rotation. As was discussed brieflyabove, the track is preferably twisted from about 0° to about 90°,although, any degree of twist can be implemented. The degree of rotationis somewhat arbitrary in that the track can be twisted a full 360° ormore if the materials of construction will allow. However, because atypical drive tape bends relatively easily in a direction transverse toits length, as is shown by tape guide tracks 16, FIG. 2, it is oftendesirable to minimize the degree of twist (i.e. the degree of rotationabout the longitudinal axis of the drive tape), and utilize the“bending” motion of the tape to complete the necessary directionalmovement of the drive tape, as is shown in FIG. 1 and FIG. 2 with thecombination of guide tracks 16 and 13.

As can be appreciated, there is a maximum degree of twist or rotationthat any drive tape can withstand for a given length of drive tape.Twisting the drive tape too quickly can cause the tape to fracture,crack or otherwise be rendered unserviceable. The maximum degree oftwist or rotation/per unit length of drive tape will necessarily dependon variables such as the material the drive tape is constructed from, aswell as the cross-sectional configuration of the drive tape, i.e., theratio of the width to the length. Size, shape and number of the drivetape perforations will also affect limitations on the ability of aparticular drive tape to be rotated or twisted. Additionally, thecarrier member, which necessarily must be rotated along with the drivetape during reciprocation along the system, will put additional forceson the drive tape and tape guide tracks due to centrifugal forces. Thus,the weight of the carrier member, the distance from the drive tape, andthe nature of the cargo being transported by the carrier member, willall effect the amount of rotation that will be appropriate per unitlength of a drive tape.

Moreover, the tape guide track may be limited in the amount of rotationper unit length, and this limitation will also depend on the material ofconstruction and the geometry of the tape guide track. However, ifnecessary, the material of construction for the tape guide track can beselected to be more flexible than the drive tape; thus obviating theneed to specifically determine the maximum degree of rotation allowablefor the tape guide track. The simplest method for determining themaximum desirable degree of twist or rotation/per unit length of aparticular drive tape is to hold one end of a predetermined length ofdrive tape in one hand and grasp the other end of the drive tape in theother hand and twist the tape until it cracks, fractures, deforms or canno longer be twisted by hand. Although crude, this method can yield anestimate for the minimum length of tape required for a given degree ofrotation. This same test can be performed mechanically, wherein two endsof a drive tape, or track guide track, can be se cured to a rotationaldevice, e.g. a lathe, and the amount of force required to rotate apredetermined length of tape, or tape guide track, a predeterminedamount, e.g. 90°, can be measured. The maximum degree of rotation can beused for design purposes as a value never to be exceeded. However, tominimize maintenance, and to avoid premature failure of the drive tape,the maximum degree of rotation used when designing guide tracks shouldgenerally be substantially less than the maximum amount of rotationallowable.

The carrier member housing 28 can similarly be made of any appropriatematerial, or combination of materials. For example, aluminum, steel,stainless steel and plastics are all suitable for carrier member housingconstruction. The size and shape of the carrier member will be dictatedprimarily by the intended cargo being transported from one station tothe next and, of course, other limitations on the conveyor system suchas space available and size of drive mechanism to be used. As seen bestin FIG. 6, the carrier housing outer side 52 is shown as comprising amesh material, although any suitable material (e.g. plastic metal or thelike) can be used.

Carrier member 10 is preferably a substantially enclosed housing havingone or more access doors, e.g., 54, FIG. 6. The cargo should be securewhile being transported between spaced apart stations, thus mesh typematerials, as shown in FIG. 6, are appropriate for enclosing carrierhousing 28 if the intended cargo cannot slip through the openings in themesh. Alternatively, means for securing cargo such as clips, clamps,belts, and the like can be used, although an enclosed housing generallyprovides the greatest degree of flexibility for the cargo to betransported there within.

Providing an easily accessible enclosed housing necessarily requires adoor or other means of selective access to the cargo within the carriermember. A reciprocable door 54 and door control mechanism 58 are shownin FIG. 6. A preferred door control mechanism 58 for reciprocable door54 is illustrated as comprising two oppositely disposed actuator arms 60attached adjacent the door sides and to carrier housing sidewalls 51with pin 62. Pin 62 provides a rotatable connection between the carrierhousing sidewalls 51 and reciprocable door 54. Additionally, a biasingmember, shown as a spring 56 in FIG. 6, preferably biases reciprocabledoor 54 to its normally closed position. In FIG. 6, reciprocable door 54is shown in its partially opened position.

In the embodiment illustrated, reciprocable door 54 is opened when cableactuator arm 72 contacts station door actuator 71 as carrier member 10is reciprocated into alignment with a station, e.g. 8, FIG. 1. Likewise,as carrier member 10 is reciprocated away from a station, cable actuatorarm 72 disengages from station door actuator 71 and spring 56 closesdoor 54. Cable actuator arm 72 preferably contacts the station dooractuator 71 near its actuator end 76, wherein actuator arm 72 pivotsabout a connector pin 78, which rotatably attaches actuator arm 72 tohousing rear wall 53. As the actuator end 76 of actuator arm 72 is movedtowards the carrier housing outer side 52, the cable end 74 of cableactuator arm 72 is moved away from carrier housing outer side 52,pulling cable 66. Cable 66 is illustrated as being connected to cableactuator arm 72 at cable connection 64, and is guided by one or morecable guide blocks (e.g. 70 and 68) pulling door actuator arm 60 so asto urge reciprocable door 54 to its open position. As can beappreciated, a variety of mechanical, electrical, hydraulic means andthe like can be equally substituted for control mechanism 58 toselectively reciprocate a carrier housing door as the carrier housing isreciprocated between spaced apart stations. The specifics of doorcontrol mechanism 58 shown in FIG. 6 are provided only as one preferredexample.

The spaced apart stations (e.g. 8, 80 and 81, FIG. 1), which the carriermember of the present invention is reciprocated between are described ingreater detail in the '605 Patent, which has been incorporated herein byreference above. The stations can be located near the end of the guidetracks, as shown in the '605 Patent and 8, FIG. 1, or can be located ata number of points along a particular guide track, e.g. 80 and 81, FIG.1. For example, a carrier member may stop at one point on a guide trackto service a person in an automobile, e.g. 81, while stopping at asecond point on the guide track to service a person in a larger vehiclesuch as a truck or van, e.g. 80. The height at which the carrier membersstops can be controlled either by an operator, e.g., a person at theother end of the guide track, or by electronic sensors incorporatedwithin the guide track as shown in the '605 Patent. Moreover, theconveyor system may include more than two stations among which a carriermay be selectively reciprocated. To accommodate communication betweenthe spaced apart stations, e.g. 8, 80 and 81, any of a variety ofcommonly used communication. Systems, e.g. 90, can be optionallyprovided with the conveyor systems of the present invention, e.g. 7.Combinations of speakers and microphones can provide one way or two waycommunication between spaced apart stations as desired.

Having shown and described the preferred embodiments of the presentinvention, further adaptations of the flexible drive system describedherein can be accomplished by appropriate modifications by one ofordinary skill in the art without departing from the scope of thepresent invention. Several of these potential modifications have beenmentioned, and others will be apparent to those skilled in the art. Forexample, guide tracks need not be mechanically twisted, but can beforged or molded into preconfigured twisted conformations. Likewise, asingle track section can be both twisted and bent to accommodate amultitude of changes in direction as opposed to each section of trackbeing either twisted, bent or straight. Similarly, while the guide trackillustrated herein is shown as comprising a plurality of connected,modular sections, a guide track could possibly be provided in a unitarycondition for particular applications. Accordingly, the scope of thepresent invention should be considered in terms of the following claimsand is understood not to be limited to the details of structure andoperation shown and described in the specification and drawings.

I claim:
 1. A tape drive system comprising: a) a push and pull drivetape including a length extending along a longitudinal axis, a widthextending along a transverse direction that is perpendicular to thelongitudinal axis, and a thickness, wherein the drive tape issubstantially flexible about an axis parallel to the transversedirection, and substantially inflexible about an axis perpendicular toboth the transverse direction and the longitudinal axis, wherein thedrive tape is capable of being used in a single drive setup; b) a tapeguide extending along a longitudinal axis, the tape guide adapted to atleast partially constrain the drive tape in the width and thicknessdirections of the drive tape, the tape guide further comprising a twistportion structured to effectively twist the drive tape about thelongitudinal axis of the drive tape; and c) a carrier attached to thedrive tape with a connector that extends through an opening defined bythe tape guide, wherein the carrier may be rotated about thelongitudinal axis of the tape guide as the carrier and drive tape areselectively reciprocated along the tape guide.
 2. The tape drive systemaccording to claim 1, wherein the tape guide further comprises a firstbend portion structured to bend the tape.
 3. The tape drive systemaccording to claim 2, wherein the tape guide further comprises a secondbend portion structured to bend the tape, and wherein the twist portionis located between the first bend portion and the second bend portion.4. The tape drive system according to claim 1, further comprising aswivel structured to attach the carrier to the tape.
 5. The tape drivesystem according to claim 1, further comprising a universal jointstructured to attach the carrier to the tape.
 6. The tape drive systemof claim 1, further comprising a second tape guide having a hollow guidetrack for at least partially housing portions of the tape.
 7. The tapedrive system according to claim 1, wherein the drive tape isnon-continuous.
 8. An improved tape guide system comprising: a) areciprocal, flexible, push and pull drive tape including a longitudinallength extending along a longitudinal axis and a predetermined widthextending along a transverse direction that is perpendicular to saidlongitudinal axis, said drive tape being substantially inflexible aboutan axis perpendicular to both said transverse direction and saidlongitudinal axis, and wherein the drive tape is capable of being usedin a single drive setup; b) a first tape guide within which said drivetape is at least partially housed, said first tape guide having two endsand a longitudinal axis extending therebetween, at least a portion ofsaid first tape guide having a twisted conformation along itslongitudinal axis, and c) a carrier attached to said drive tape, whereinsaid carrier may be rotated about said longitudinal axis of said tapeguide as said carrier and drive tape are selectively reciprocated alongsaid tape guide.
 9. The tape guide system of claim 8, wherein said firsttape guide further comprises a longitudinal channel extending along saidlongitudinal axis of said first tape guide for receiving and guidingsaid drive tape, and wherein said first tape guide has an outer surfaceand said longitudinal channel and said outer surface of at least saidportion of said first tape guide are twisted along said longitudinalaxis of said first tape guide such that said outer surface is at leastpartially rotated relative to said longitudinal axis of said first tapeguide.
 10. The tape guide system of claim 9, wherein said outer surfaceand said longitudinal channel of at least said portion of said firsttape guide are twisted between 0° and 90° relative to said longitudinalaxis of said first tape guide.
 11. The tape guide system of claim 8,wherein said tape guide comprises a hollow guide track for at leastpartially housing the tape.
 12. The tape guide system of claim 11,further comprising a second tape guide, having a hollow guide track forat least partially housing portions of the tape.
 13. The tape guidesystem of claim 11, wherein said tape guide comprises a plurality ofmodular sections which can be connected as desired to provide customsystems designs.
 14. The tape guide system of claim 8, wherein the drivetape is non-continuous.
 15. A method of conveying an item comprising thesteps of: a) providing a tape drive system comprising a push and pulldrive tape including a length extending along a longitudinal axis, awidth extending along a transverse direction that is perpendicular tothe longitudinal axis, and a thickness, wherein the drive tape issubstantially flexible about an axis parallel to the transversedirection, and substantially inflexible about an axis perpendicular toboth the transverse direction and the longitudinal axis, wherein thedrive tape is capable of being used in a single drive setup, and a tapeguide extending along a longitudinal axis and structured to at leastpartially constrain the drive tape in the width and thickness directionsof the drive tape, the tape guide further comprising a twist portion; b)attaching a carrier to the drive tape; and c) actuating the drive tapeto move in the longitudinal direction of the drive tape such that thecarrier may be rotated about the longitudinal axis of the tape guide asthe carrier and drive tape are selectively reciprocated along the twistportion of the tape guide.
 16. The method of claim 15, furthercomprising the step of effectively twisting the tape about itslongitudinal axis.
 17. The method of claim 15, wherein the step ofactuating the tape includes reciprocating the tape in the tape guide.18. The method of claim 17, wherein said tape is reciprocated between aplurality of stations.
 19. The method of claim 16, further comprisingthe step of providing said tape guide with at least one bend portion,whereby said tape will be bent to alter the direction of orientation ofthe carrier as it is conveyed.
 20. The method of claim 15, furthercomprising the step of providing a moveable attachment between thecarrier and the tape, whereby limited movement between these elements isfacilitated during activation of the tape to accommodate stresses andstrains during conveying operations.
 21. The method of claim 15, whereinthe step of providing a tape drive system comprises providing a tapedrive system wherein the tape is non-continuous.